Grooved Drum and Associated Roller for Motorized Lifting Device

ABSTRACT

An apparatus includes a drum to draw in or let out a line and a motor coupled to the drum to apply a torque thereto. The drum includes a groove formed in an outer surface thereof to accommodate the line. A roller is provided that tracks the groove and extends into the groove. The roller pushes the line into the groove. In certain embodiments, the roller pushes the line to a bottom of the groove to ensure that the line is properly seated therein.

RELATED APPLICATIONS

This application claims priority to U.S. Provisional Patent No.61/822,644 filed on May 13, 2013 and entitled “A Winch System ComprisingInsulated Cables”; U.S. Provisional Patent No. 61/924,157 filed on Jan.6, 2014 and entitled “Cable Guide”; U.S. Provisional Patent No.61/925,144 filed on Jan. 8, 2014 and entitled “Smart Lift”; U.S.Provisional Patent No. 61/925,182 filed on Jan. 8, 2014 and entitled“Smart Multi Lift”; and U.S. Provisional Patent No. 61/933,508 filed onJan. 30, 2014 and entitled “Lift Platform”.

This application is a continuation of U.S. patent application Ser. No.14/245,495 filed on Apr. 4, 2014 and entitled “Motorized Lifting DeviceConveying Power and/or Data”; which is a continuation of U.S. patentapplication Ser. No. 14/245,396 filed on Apr. 4, 2014 and entitled “LoadDistribution Management for Groups of Motorized Lifting Devices”; whichis a continuation of U.S. patent application Ser. No. 14/245,308 filedon Apr. 4, 2014 and entitled “Accurate Position Tracking for MotorizedLifting Device”; which is a continuation of U.S. patent application Ser.No. 14/245,234 filed on Apr. 4, 2014 and entitled “Intelligent MotorizedLifting Device”; which is a continuation of U.S. patent application Ser.No. 14/245,132 filed on Apr. 4, 2014 and entitled “SynchronizedMotorized Lifting Devices for Lifting Shared Loads”; which is acontinuation of U.S. patent application Ser. No. 14/245,095 filed onApr. 4, 2014 and entitled “Motorized Lifting Device with Accurate WeightMeasuring Capability”; which is a continuation of U.S. patentapplication Ser. No. 14/245,055 filed on Apr. 4, 2014 and entitled“Motorized Lifting Device with Isolated Logistics and PowerElectronics”; which is a continuation of U.S. patent application Ser.No. 14/245,000 filed on Apr. 4, 2014 and entitled “Locking Mechanism forMotorized Lifting Device”; which is a continuation of U.S. patentapplication Ser. No. 14/244,771 filed on Apr. 3, 2014 and entitled“Compact Motorized Lifting Device”.

BACKGROUND

1. Field of the Invention

This invention relates to hoists, winches, and other pulling and/orlifting devices.

2. Background of the Invention

Hoists and winches are used extensively to lift, lower, or pull loads ofvarious kinds Such devices typically include a line, such as a cable orchain, wrapped around a spool. To lift, lower, or pull a load, the spoolmay be manually rotated or driven with a motor, such as an electrical,hydraulic, or pneumatic motor. When rotation is not desired, a brakingmechanism may be used to prevent the spool from turning. This maymaintain tension in the line, keep a load suspended, or prevent therelease or unspooling of the line. To keep the line from bunching on thespool, some hoists or winches may include guides or other mechanisms toevenly wind the line around the spool.

Although a wide variety of hoists and winches are available, many haveshortcomings that prevent or discourage their use in variousapplications. For example, some hoists or winches are bulky orcumbersome, which may prevent their use in applications where greatercompactness is required or desired. Other hoists and winches may beeconomically infeasible for use in applications such as consumer orresidential applications due to their complexity or expense.

The accuracy and precision of some hoists and winches may also belacking in certain applications. For example, because the line of ahoist or winch may be wound around itself in an irregular orunpredictable manner, the effective diameter of the spool may change forline that is drawn in or let out from the spool. The result is that, forany given angle of rotation of the spool, an unpredictable amount ofline may be drawn in or let out. This can make the hoist or winchunsuitable for applications where a high degree of precision isrequired. It can also make the winch or hoist unsuitable for operationsthat require a high degree of repeatability.

Some hoists and winches may also have shortcomings in terms of thecontrol and information they provide. For example, current hoists andwinches may lack mechanisms for determining certain parameters duringoperation. For example, short of manually measuring or observing a hoistor winch, it may be difficult or impossible to determine how much lineis let out from the hoist or winch at any given time. Even if possible,it may not be possible to do so with a desired degree of precision. Inother cases, the ability to determine a load on the hoist or winch, oradjust the speed of a hoist or winch (which may depend on the load) maybe lacking. In yet other cases, an event such as a power outage or resetmay cause a hoist or winch to forget or lose information regardingcurrent operating parameters.

As with most fields of endeavor, improvements are constantly soughtafter by those of skill in the art. As it relates to hoists and winches,improvements are needed to address bulkiness, complexity, expense,precision, and control, as discussed herein. Ideally, such improvementswill create new applications for hoists or winches, or make hoists orwinches more economically or practically feasible for existingapplications.

SUMMARY

The invention has been developed in response to the present state of theart and, in particular, in response to the problems and needs in the artthat have not yet been fully solved by currently available apparatus andmethods. Accordingly, apparatus and methods in accordance with theinvention have been developed to provide improved motorized lifting orpulling devices. The features and advantages of the invention willbecome more fully apparent from the following description and appendedclaims, or may be learned by practice of the invention as set forthhereinafter.

In a first embodiment of the invention, an apparatus includes a motorand a drum rotated by the motor to draw in or let out a line from thedrum. The drum includes a groove formed in an outer surface thereof toaccommodate the line. In certain embodiments, a depth of the groove isequal to or greater than a radius of the line. In the same or otherembodiments, a passive guide that physically engages and tracks thegroove may be used to guide the line into the groove.

In a second embodiment of the invention, an apparatus includes a drum todraw in or let out a line, and a motor and transmission coupled to thedrum to apply a torque thereto. In certain embodiments, the motor andtransmission are substantially entirely contained within the drum. Inthe same or other embodiments, a bearing may provide support for boththe transmission and the drum.

In a third embodiment of the invention, an apparatus includes a drum todraw in or let out a line and a motor and transmission coupled to thedrum to apply a torque thereto. The transmission includes at least onestage of gearing to reduce a gear ratio of the motor relative to thedrum. A shaft couples the motor to the transmission and a lockingmechanism selectively locks the shaft to prevent rotation of the drum.In certain embodiments, a braking mechanism may be provided in additionto the locking mechanism to slow the motor when the motor is notapplying torque to the drum. This may slow the motor sufficiently toenable engagement of the locking mechanism.

In a fourth embodiment of the invention, an apparatus includes a drum todraw in or let out a line and a motor and transmission coupled to thedrum to apply a torque thereto. Logistics electronics are mountedproximate a first end of the drum and power electronics are mountedproximate a second end of the drum. In general, the logisticselectronics include lower power electronics that enable data processingas well as data and commands to be communicated to the apparatus from anexternal location. By contrast, the power electronics may include higherpower electronics needed to receive power and drive the motor.

In a fifth embodiment of the invention, an apparatus includes a drum todraw in or let out a line and a motor and transmission coupled to thedrum to apply a torque thereto. A power sensor measures an amount ofcurrent drawn and/or voltage supplied to the motor as the motor appliestorque to the line. A processor calculates an amount of weight that isattached to the line based on the amount of power consumed by the motor.Alternatively, if the motor is operated in generator mode, a currentsensor may measure an amount of current generated by the motor and theprocessor may calculate an amount of weight that is attached to the linebased at least partly on an amount of current that is generated by themotor.

In a sixth embodiment of the invention, a system includes multiplelifting devices, where each lifting device includes a drum to draw in orlet out a line, and a motor and transmission coupled to the drum toapply a torque thereto. A grouping module is provided to group thelifting devices for synchronized operation. A synchronization modulemonitors an amount of line that is drawn in or let out from each of thelifting devices and, based on the amount, adjusts operating parameters(e.g., position, speed, etc.) of one or more of the lifting devices inthe group to substantially synchronize the amount of line drawn in orlet out with other lifting devices in the group.

In a seventh embodiment of the invention, an apparatus includes a drumto draw in or let out a line and a motor and transmission coupled to thedrum to apply a torque thereto. A tracking module tracks an actualamount of line let out from the drum. A servo control unit receives theactual amount, compares the actual amount to a desired amount of line tolet out from the drum, and generates an error signal reflecting adifference between the actual amount and the desired amount. Amodulation module generates, from the error signal, a control signal tocontrol the motor, thereby bringing the actual amount into betteralignment with the desired amount.

In an eighth embodiment of the invention, an apparatus includes a drumto draw in or let out a line and a motor and transmission coupled to thedrum to apply a torque thereto. An encoder is provided to measure anangular position of the drum. A counter is provided to record a numberof rotations of the drum. A locking mechanism automatically preventsrotation of the drum when the drum stops. Using this information, aprocessor may calculate an amount of line let out from the drum based onthe number of rotations of the drum, the angular position of the drum,and a radius of the drum. In certain embodiments, the angular positionand/or number of rotations is stored in non-volatile memory so that iscan be recovered in the event of a power outage or other significantevent.

In a ninth embodiment of the invention, a system includes multiplelifting devices, where each lifting device includes a drum to draw in orlet out a line, and a motor and transmission coupled to the drum toapply a torque thereto. A grouping module groups the lifting devices forsynchronized operation in lifting a shared load. A load distributionmanagement module monitors an amount of weight carried by each of thegrouped lifting devices and provides feedback to a user to enable moreoptimal distribution of the shared load amongst the grouped liftingdevices.

In a tenth embodiment of the invention, an apparatus includes a drum todraw in or let out a line and a motor and transmission coupled to thedrum to apply a torque thereto. A cable is incorporated into the line totransport at least one of power and data along the line to an object ordevice at the end of the line. In certain embodiments, the cable isconfigured to support all or a portion of the load. In otherembodiments, the line includes a load-bearing wire separate from thecable which is configured to support all or a portion of the load.

In an eleventh embodiment of the invention, an apparatus includes a drumto draw in or let out a line and a motor coupled to the drum to apply atorque thereto. The drum includes a groove formed in an outer surfacethereof to accommodate the line. A roller is provided that tracks thegroove and extends into the groove. The roller pushes the line into thegroove. In certain embodiments, the roller pushes the line to a bottomof the groove to ensure that the line is properly seated therein.

BRIEF DESCRIPTION OF THE DRAWINGS

In order that the advantages of the invention will be readilyunderstood, a more particular description of the invention brieflydescribed above will be rendered by reference to specific embodimentsillustrated in the appended drawings. Understanding that these drawingsdepict only typical embodiments of the invention and are not thereforeto be considered limiting of its scope, the invention will be describedand explained with additional specificity and detail through use of theaccompanying drawings, in which:

FIG. 1 is a perspective view showing one embodiment of a motorizedlifting device in accordance with the invention;

FIG. 2 is an alternative perspective view of the motorized liftingdevice illustrated in FIG. 1;

FIG. 3 is another alternative perspective view of the motorized liftingdevice illustrated in FIG. 1;

FIG. 4 is a side view of a motorized lifting device provided to show thegrooved drum and line;

FIG. 5 is a side view of the grooved drum illustrated in FIG. 4;

FIG. 6 is a perspective view of one embodiment of a passive guide toguide the line into the grooved drum;

FIG. 7 is a cutaway perspective view of the passive guide interfacingwith the grooved drum;

FIG. 8 is a cutaway side view of the passive guide interfacing with thegrooved drum;

FIG. 9A is a perspective view of one embodiment of a motorized liftingdevice comprising a rolling mechanism to assist the passive guide inguiding line into the grooved drum;

FIG. 9B is an end view of the motorized lifting device of FIG. 9A;

FIG. 10A is a perspective view of another embodiment of a rollingmechanism to assist the passive guide in guiding line into the grooveddrum;

FIG. 10B is a close-up view of the rolling mechanism of FIG. 10A;

FIG. 11 is an internal view of one embodiment of a motorized liftingdevice with various components removed to facilitate viewing of otherinternal components;

FIG. 12 is a cutaway side view of a motorized lifting device showingvarious internal components;

FIG. 13 is a cutaway perspective view of a motorized lifting deviceshowing various internal components;

FIG. 14 is an internal perspective view of one embodiment of a lockingmechanism in accordance with the invention;

FIG. 15 is a cutaway top view of the locking mechanism illustrated inFIG. 14 when the locking mechanism is disengaged;

FIG. 16 is a cutaway top view of the locking mechanism illustrated inFIG. 14 when the locking mechanism is engaged;

FIG. 17 is an internal perspective view of another embodiment of alocking mechanism in accordance with the invention, with the lockingmechanism engaged;

FIG. 18 is an internal perspective view of the locking mechanism of FIG.17 with the locking mechanism disengaged;

FIG. 19 is a side view of the locking mechanism of FIG. 17 with thelocking mechanism engaged;

FIG. 20 is a side view of the locking mechanism of FIG. 17 with thelocking mechanism disengaged;

FIG. 21 is a side view of an actuator for use with the locking mechanismof FIG. 17 where the actuator is positioned to disengage the lockingmechanism;

FIG. 22 is a side view of the actuator of FIG. 21 where the actuator ispositioned to engage the locking mechanism;

FIG. 23A is an internal view of another embodiment of a lockingmechanism in accordance with the invention, with the locking mechanismengaged;

FIG. 23B is an internal view of the locking mechanism of FIG. 23A withthe locking mechanism disengaged;

FIG. 24A is a side view of the locking mechanism of FIG. 23A with thelocking mechanism engaged;

FIG. 24B is a side view of the locking mechanism of FIG. 23B with thelocking mechanism disengaged;

FIG. 25 is a perspective view of another embodiment of a lockingmechanism in accordance with the invention, in this example arack-and-pinion-type locking mechanism;

FIG. 26A is a close-up view of the locking mechanism of FIG. 25, withthe locking mechanism disengaged;

FIG. 26B is a close-up view of the locking mechanism of FIG. 25, withthe locking mechanism engaged;

FIG. 27 is a diagram showing one or more set points for a motorizedlifting device in accordance with the invention;

FIG. 28 is a diagram showing how set points may be used to lift andlower an object, in this example a bicycle;

FIG. 29 is a high-level view of one embodiment of a user interface forcontrolling a motorized lifting device in accordance with the invention,the user interface implemented on a mobile general-purpose processingdevice such as a smart phone;

FIG. 30 is a high-level view of one embodiment of a user interface forcontrolling a motorized lifting device in accordance with the invention,the user interface implemented on a dedicated remote control;

FIG. 31 is a high-level view of a group of motorized lifting devicesconfigured for synchronized operation;

FIG. 32 is a high-level view of a user interface for managing a loaddistributed between multiple motorized lifting devices;

FIG. 33 is a perspective view of one embodiment of a quick mountingsystem for a motorized lifting device in accordance with the invention;

FIG. 34 is a block diagram showing how a motorized lifting device inaccordance with the invention may calculate the weight of a load;

FIG. 35A is a graph showing an output from a resistive encoder;

FIG. 35B is a graph showing a combined output from two rotationallyoffset resistive encoders;

FIG. 35C is a graph showing an output from a magnetic encoder;

FIGS. 36A-D are several views of one embodiment of a connector for usewith a motorized lifting device in accordance with the invention;

FIGS. 37A and 37B are several views of another embodiment of a connectorfor use with a motorized lifting device in accordance with theinvention;

FIG. 38 is a high-level view of various hardware components that may beused in a motorized lifting device in accordance with the invention;

FIG. 39 is a high-level view showing various functions that my beprovided by the hardware components of FIG. 38; and

FIG. 40 is a block diagram showing various modules, implemented inhardware and/or software, that perform various features and functions inassociation with the motorized lifting device.

DETAILED DESCRIPTION

It will be readily understood that the components of the presentinvention, as generally described and illustrated in the Figures herein,may be arranged and designed in a wide variety of differentconfigurations. Thus, the following more detailed description of theembodiments of the invention, as represented in the Figures, is notintended to limit the scope of the invention, as claimed, but is merelyrepresentative of certain examples of presently contemplated embodimentsin accordance with the invention. The presently described embodimentswill be best understood by reference to the drawings, wherein like partsare designated by like numerals throughout.

Referring to FIG. 1, a perspective view showing one embodiment of amotorized lifting device 10 in accordance with the invention isillustrated. Although the motorized lifting device 10 is describedherein primarily as it relates to lifting objects, the device 10 mayalso be used to pull loads in the manner of conventional winches. Thus,nothing in this disclosure should be interpreted as indicating that themotorized lifting device 10 is only suitable for lifting. Many of thefeatures and functions described herein related to lifting may beequally beneficial to pulling loads.

As will be explained in more detail hereafter, the motorized liftingdevice 10 may address a multitude of different shortcomings of the priorart, such as problems with bulkiness, precision, and control. Suchimprovements will ideally create new applications for hoists or winches,or make hoists or winches more economically or practically feasible forexisting applications. As will be explained in more detail hereafter,the illustrated motorized lifting device 10 is compact relative to otherdevices with similar capability and function, and has features toprovide improved precision and control. In some respects, the precisionand control of the motorized lifting device 10 is similar to theprecision and control provided by modern-day computer numerical control(CNC) machine tools. For example, the features and functions of themotorized lifting device 10 make it possible to know at all times wherethe end of the line is, or position the end of the line at a desiredlocation. This capability enables a wide variety of other features andfunctions, the likes of which will be explained in more detailhereafter.

FIG. 1 provides an external view of one embodiment of a motorizedlifting device 10. Many internal features are hidden from view. Suchinternal features will be illustrated and described in the Figures anddescription that follow. As shown in FIG. 1, the motorized liftingdevice 10 includes a frame 12, a drum 14 for letting out or drawing in aline 16, and a passive guiding mechanism 18 for guiding the line 16 ontoor off of the drum 14. In the illustrated embodiment, the drum 14 isgrooved. That is, the drum 14 includes a continuous groove (e.g. ahelical groove) around a circumference thereof. This allows the drum 14to receive and retain the line 16 in the groove. The advantages providedby the grooved drum 14 will be described in more detail hereafter. Thegrooved drum 14 is rotated by a motor and transmission (not shown),which in the illustrated embodiments are substantially entirelycontained within the grooved drum 14. This makes the motorized liftingdevice 10 very compact and potentially expands a number of applicationsfor the device 10. The motor and transmission are illustrated anddescribed in association with FIGS. 11 through 13.

Other details of FIG. 1 are worth noting. As shown in FIG. 1, the frame12 of the motorized lifting device 10 includes a pair of flanges 20. Theflanges 20 may enable the motorized lifting device 10 to be quickly andeasily connected to a bracket (not shown) with pins, bolts, or otherfasteners. Such a bracket may be attached to a ceiling joist, wall stud,or other structural member, as will be explained in more detail inassociation with FIG. 33. The flanges 20 may also allow the motorizedlifting device 10 to be quickly and easily removed or attached toanother bracket in a different location. Thus, the motorized liftingdevice 10 may be configured for quick and easy attachment and removalfrom ceilings, walls, or the like.

As shown, the motorized lifting device 10 includes cover plates 22 ateach end. In certain embodiments, the cover plates 22 cover electronicslocated at the ends of the motorized lifting device 10. For example, aswill be explained in more detail hereafter, logistics electronics may bemounted at or near a first end of the motorized lifting device 10 andpower electronics may be mounted at or near a second end of themotorized lifting device 10. The logistics electronics may include lowerpower electronics such as data processing microelectronics orcommunication electronics that enable data and commands to becommunicated to the motorized lifting device 10 from an externallocation. The power electronics may include higher power electronics toreceive power and drive the motor. Placing the logistics electronics andpower electronics on separate ends of the motorized lifting device 10may prevent noise, generated by the power electronics, from interferingwith operation of the logistics electronics. In certain embodiments, apower and/or data cable 24, such as a ribbon cable, may be routed acrossa top of the frame 12 to enable power and/or data to be communicatedbetween the logistics electronics and the power electronics.

As shown, a passive guiding mechanism 18 guides the line 16 into thegroove of the drum 14. As will be explained in more detail hereafter,the passive guiding mechanism 18 may include a passive guide 26 thatmoves along a slide 28 substantially perpendicular to the groove. Incertain embodiments, the slide 28 is retained by a pair of arms 30 thatextend from the motorized lifting device 10. The passive guide 26 mayinclude one or more teeth that ride in and track the groove as the drum14 rotates. When the drum 14 rotates in a first direction, the passiveguide 26 guides the line 16 into the groove. When the drum 14 rotates inan opposite direction, the passive guide 26 guides the line 16 out ofthe groove. The passive guide 26 is referred to as “passive” because noadditional power source is needed to move the passive guide 26 along theslide 28. Rotation of the drum 14 combined with tracking of the grooveis sufficient to move the passive guide 26 along the slide 28 and guidethe line 16 into or out of the groove.

FIGS. 2 and 3 show the motorized lifting device 10 of FIG. 1 from twoalternative vantage points. FIG. 1 shows the motorized lifting device 10from an end housing the logistics electronics and FIG. 2 shows themotorized lifting device 10 from an end housing the power electronics.As shown in FIG. 2, the end housing the power electronics includes acable 32 for supplying power thereto. The end also includes vents 34 forreleasing heat generated by the motor and/or power electronics. FIG. 2also provides a view of an underside of the passive guide 26substantially conforming to a curvature of the grooved drum 14. FIG. 3provides a top view of the motorized lifting device 10, particularlyshowing the cable 24 extending between the logistics electronics andpower electronics on opposite sides of the drum 14.

Referring to FIG. 4, a side view of the motorized lifting device 10showing the grooved drum 14 and line 16 is illustrated. As previouslymentioned, the drum 14 may include a continuous groove, such as ahelical groove, around a circumference thereof. This groove may receivethe line 16 and prevent the line 16 from winding over itself as the drum14 rotates. To fit within the groove, the line 16 may be equal to orshorter than a length of the groove. Because the line 16 is situated inthe groove and the radius of the drum 14 is known, the amount of linelet out from or drawn into the motorized lifting device 10 may beprecisely calculated from the angular position and number of rotationsof the drum 14. Thus, the grooved drum 14 may enable precisecalculations of how much line 16 is drawn in or let out from themotorized lifting device 10 at any given time.

As previously mentioned, the passive guiding mechanism 18 may rely onthe grooved drum 14 to guide the line 16 into the groove. That is, asthe drum 14 rotates, teeth or other surface features on the passiveguide 26 may track the groove to move the passive guide 26 along theslide 28. This enables the passive guide 26 to precisely guide the line16 into or out of the groove as the drum 14 rotates.

In certain embodiments, the groove is sized to grip the line 16 disposedtherein. That is, the sides of the groove may be configured to pressslightly against the line 16 in order to grip the line 16. Thus, incertain embodiments, the width of the groove is the same or slightlysmaller than a diameter of the line 16. Furthermore, in order to gripthe line 16, the groove may be configured to be at least as deep as aradius of the line 16. This will allow the sides of the groove to reacharound and grip the sides of the line 16.

In other embodiments, the groove may be deeper than a radius of the line16. This may provide a better grip on the line 16 as well as provide asurface to guide the passive guide 26. Thus, in certain embodiments thegroove is deeper than a radius of the line 16. In yet other embodiments,the groove is at least as deep as a diameter of the line 16. In yetother embodiments, such as in the embodiment illustrated in FIG. 4, thegroove is substantially deeper than a diameter of the line 16. This willallow the line 16 to fit entirely within the groove and still providesome groove depth to accommodate teeth or other surface features of thepassive guide 26.

In certain embodiments, surfaces of the drum 14 or line 16 may beprepared, coated, or textured to provide the capabilities discussedabove. For example, if the line 16 comprises a metal cable, the cablemay be coated with a material such as rubber or plastic to enable bettergripping. Similarly, the drum 14 may be fabricated from a material, ortextured or coated with a material that provides an improved grip on theline 16. By contrast, other parts of the drum 14 may be configured toreduce friction. For example, upper sides of the groove or an outersurface of the drum 14 may be smoothed, lubricated, or the like toreduce friction between the passive guide 26 and the groove or drum 14.

Referring to FIG. 5, a side view of the grooved drum 14 illustrated inFIG. 4 is shown. As shown, the grooved drum 14 includes a groove 36, inthis example a helical groove 36, around a circumference thereof. Inthis example, the groove 36 includes a curved bottom that roughlyconforms to a curvature of the line 16, although this may not benecessary in all embodiments. A shoulder 38 resides on each side of thegroove 36. As shown, assuming a line 16 has approximately the same widthas the groove 36, the groove 36 is significantly deeper than a diameterof the line 16. This will ensure that the line 16 can fit entirelywithin the groove and still provide some groove depth to enable trackingof the passive guide 26.

Referring to FIG. 6, while also referring generally to FIG. 7, aperspective view of one embodiment of a passive guide 26 and slide 28for guiding a line 16 into a grooved drum 14 is illustrated. As shown,the passive guide 26 has a curved surface 46 substantially conforming toa curvature of the grooved drum 14. This surface 46 includes a pluralityof teeth 42 that ride in and track the groove 36. These teeth 42 alsohave a curvature that generally conforms to the curvature of the drum14. In the illustrated embodiment, the passive guide 26 includes threeteeth 42, with the center tooth 42 cut away to provide a passage 40 forthe line 16.

The passive guide 26 includes an aperture 44 to accommodate and guidethe line 16. The illustrated aperture 44 is elongate in the direction ofthe groove 36 to allow freedom of movement in the direction of thegroove 36 while limiting movement transverse to the groove 36. This willideally keep the line 16 aligned with the groove 36 and prevent the line16 from jumping over a shoulder 38. In certain embodiments, rollers,bearings, rounded surfaces, or other friction-reducing components may beprovided inside the aperture 44 to reduce friction on the line 16.Alternatively, the aperture 44 may include means to slightly grip theline 16 as it passes through the aperture 44. For example, a slight gripon the line 16 may keep the line 16 slightly tensioned around the drum14, thereby preventing slack in the line 16 and possible unraveling. Incertain embodiments, a set screw or other adjustment mechanism may beprovided to set or adjust the grip on the line 16.

The amount of grip on the line 16 may be tuned to maintain tensionaround the drum 14 and prevent bunching of the line 16 when line 16 islet out from the motorized lifting device 10. Bunching may occur, forexample, when line is let out from the motorized lifting device 10 butthere is little or no weight at the end of the line 16. Thus, if a gripis too tight on the line 16, the line 16 may bunch around the drum 14instead of passing through the aperture 44 as line 16 is let out. Toprevent this, the amount of grip on the line 16 may be finely tuned. Incertain embodiments, rigidity in the line 16, such as may exist withvarious types of wire cables (e.g., steel cables), may assist the line16 in pushing through the slight grip to prevent bunching around thedrum 14.

As shown, the slide 28 is circular, thereby allowing the passive guide26 to rotate around the slide 28 absent any other constraints. However,the passive guide's curvature combined with its close proximity to thedrum 14 (as shown in FIG. 7) will keep the passive guide 26 fromrotating around the slide 28. Rather the passive guide 26 will beconfined to lateral movement along the slide 28 as the passive guide 26tracks the groove 36 of the drum 14.

Although a cross-section of the slide 28 is circular in the illustratedembodiment, the cross-section of slide 28 is not limited to circularcross-sections. Non-circular cross-sections may also be used in someembodiments. Such non-circular cross-sections may be able to preventrotation of the passive guide 26 around the slide 28 without any otherconstraints, while still allowing the passive guide 26 to move laterallyalong the slide 28. Because additional constraints may be unneeded, thecurved surface 46 of the passive guide 26 may be replaced with othersurface types, including surfaces with a smaller surface area ornon-curved surfaces.

Referring to FIG. 8, a cutaway side view of the passive guide 26interfacing with the grooved drum 14 is illustrated. As shown in FIG. 8,the groove 36 is significantly deeper than a diameter of the line 16,thereby providing sufficient groove depth to accommodate the teeth 42 ofthe passive guide 26. Dotted circles 48 are provided to show theapproximate space occupied by the line 16. The teeth 42 may fill anyremaining space in the groove 36. One additional function provided bythe teeth 42 is that they may push the line 16 into the groove 36, suchas to the bottom of the groove 36. This may increase the accuracy of themotorized lifting device 10 since the amount of line 16 let out from themotorized lifting device 10 may be a function of the angular position ofthe drum 14, the number of rotations of the drum 14, and the radius ofthe drum 14. If the line 16 is not properly seated within the groove 36,the effective radius of the line 16 may differ from the radius of thedrum 14. This may increase error and undermine the ability to accuratelydetermine how much line is let out from the drum 14 at any given time.

Referring to FIG. 9A, in certain embodiments, an additional roller 50may provide assistance in keeping the line 16 in the groove 36. Forexample, the roller 50 may be configured to lead or trail the passiveguiding mechanism 18 to ensure that the line 16 is retained in thegroove 36 and to prevent the line 16 from unwinding, bunching, ortangling when little or no weight is attached to the end of the line 16.In certain embodiments, additional arms 52 may extend from the motorizedlifting device 10 to hold the roller 50. The roller 50 illustrated inFIG. 9A is substantially smooth, meaning that it may not fully penetratethe groove 36 and/or not always make contact with the line 16 in thegroove 36. Nevertheless, in certain embodiments, the roller 50 may befabricated from a soft or deformable material such as rubber to somewhatpenetrate the groove 36 as it presses thereagainst. In otherembodiments, the roller 50 may be fabricated from a firm or inelasticmaterial. FIG. 9B shows a side view of the motorized lifting device 10of FIG. 9A.

Referring to FIGS. 10A and 10B, another embodiment of a rollingmechanism is illustrated. In this embodiment, instead of extending thelength of the drum 14, like the roller 50 described in FIGS. 9A and 9B,a roller 51 may be narrow enough to fit or at least partially fit withinthe groove 36. This allows the roller 51 to extend into the groove 36and thereby push the line 16 into the groove 36. This may also help toensure that the line 16 is fully seated in the groove 36. Such a featuremay be particularly beneficial in cases where the groove 36 is slightlynarrower than the line 16 or exerts a slight grip on the line 16, sincesome force or urging may be needed to fully seat the line 16 in thegroove 36. This feature may also improve the precision of the motorizedlifting device 10, since seating the line 16 in the groove 36 may beimportant to accurately determine how much line 16 is let out at anygiven time. Ensuring the line 16 is fully seated in the groove 36ensures that the effective radius of the drum 14 is substantially equalto its actual radius.

As shown in FIGS. 10A and 10B, in certain embodiments, the roller 51 maybe incorporated into the passive guide 26. This will enable the roller51 to move with the passive guide 26 along the slide 28, therebyallowing the roller 51 to track and follow the helical groove 36. Theroller 51 may also provide a benefit when letting out line 16 from thedrum 14, particularly when there is little or no weight attached to theend of the line 16. When letting out line 16, the line 16 has thepotential to unwind or bunch on the drum 14 since little or no weight ispresent to pull the line 16 through the passive guide 26. In otherwords, the line 16 may unwind around the drum 14 instead of feedingthrough the passive guide 26. The roller 51 may help to prevent such aproblem by keeping the line 16 positioned or pressed against a bottom ofthe groove 36 while the line 16 is being let out.

Also worth noting in FIGS. 10A and 10B is a wheel 53 or bearing 53within the passive guide 26. As previously mentioned, rollers, bearings,rounded surfaces, or other friction-reducing components may be providedinside the passive guide 26 to reduce friction when drawing in orletting out the line 16. FIGS. 10A and 10B show one example of such awheel 53 or bearing 53. In certain embodiments, this wheel 53 or bearing53 may assist in pushing the line 16 into the groove 36 as well asretaining the line 16 in the groove 36 once inside.

Referring to FIGS. 11 through 13, several internal views of a motorizedlifting device 10 in accordance with the invention are provided. FIG. 11is an internal view of a motorized lifting device 10 showing a motor 54,locking mechanism 62, and gearbox 56 (also referred to as a transmission56). Selected components, such as the drum 14, bearings 66, and ringgear 64 of the gearbox 56 have been removed from FIG. 11 to facilitateviewing of other internal components. FIG. 12 is a cutaway side view ofthe motorized lifting device 10 showing internal components. FIG. 13 isa cutaway perspective view of the motorized lifting device 10 alsoshowing internal components.

As shown in FIGS. 11 through 13, a motorized lifting device 10 inaccordance with the invention includes a motor 54 to provide arotational force or torque. In certain embodiments, the motor is adirect current (DC) motor, such as a low voltage DC motor, althoughother types of motors may also be used. The motor 54 may be coupled to agearbox 56 to reduce the gear ratio of the motor. In the illustratedembodiment, an output shaft 74 of the motor 54 is coupled to a pinion72, which in turn drives the gearbox 56. An output hex 60 (or othershape) may act as an output shaft of the gearbox 56 to drive the drum14. In the illustrated example, the gearbox 56 is a planetary gearbox 56comprising multiple stages of planet carriers/pinions 80 and planetarygears 78. These stages of planet carriers/pinions 80 and planetary gears78 rotate within a ring gear 64 to reduce the gear ratio of the motor54. Each successive stage of planetary gears 78 may reduce the gearratio by a selected amount in accordance with the principles governingplanetary gears.

For example, assume that each stage of planetary gears 78 reduces thegear ratio by five. In such a scenario, the planet carrier/pinion 80 amay rotate fives times slower than the pinion 72 (which is directlycoupled to the motor 54); the planet carrier/pinion 80 b may rotatetwenty-five (i.e., 5²) times slower than the pinion 72; the planetcarrier/pinion 80 c may rotate one hundred and twenty-five (i.e., 5³)times slower than the pinion 72; and the output hex 60 (also acting as aplanet carrier 60 and output shaft of the gearbox 56) may rotate sixhundred and twenty-five (i.e., 5⁴) times slower than the pinion 72.Thus, in this example, the gearbox 56 rotates the drum 14 a single timefor every six hundred and twenty-five rotations of the motor 54. Thisrepresents one example of a gear ratio for a gearbox 56 and is notintended to be limiting. Other gear box designs and gear ratios arepossible and within the scope of the invention. One of ordinary skill inthe art will recognize that the relative sizes of the pinions 72, 80 a,80 b, 80 c and planetary gears 78 may be varied as well as the number ofstages to alter the gear ratio.

One notable feature of the illustrated motorized lifting device 10 isthat the motor 54 and gearbox 56 are substantially entirely containedwithin the drum 14. This substantially reduces the size of the motorizedlifting device 10. This, in turn, may increase a number of applicationsfor the motorized lifting device 10, particularly applications wherecompactness is desired or required.

Another notable feature of the illustrated motorized lifting device 10is the output hex 60. Instead of using an output shaft, like mostgearboxes or transmissions, the illustrated motorized lifting device 10uses an output hex 60 to drive the drum 14. The output hex 60 alsofunctions as a planet carrier for the last stage of planetary gears 78.In other words, the output hex 60 may include pins (now shown) thatenable rotation of the last stage of planetary gears 78. The drum 14includes a corresponding hex-shaped recess into which the output hex 60fits, thereby enabling the output hex 60 to apply a torque to the drum14. In other words, the output hex 60 may act as a key and the drum 14may provide a socket into which the key fits. The hex shape of theoutput hex 60 ensures that the output hex 60 stays rotationally lockedrelative to the drum 14. Although, the output hex 60 is hexagonallyshaped in the illustrated embodiment, other shapes are also possible andwithin the scope of the invention, as long as the selected shape has theability to lock with a corresponding recess in the drum 14.

Another notable feature of the motorized lifting device 10 is the use ofa common bearing 66 to support the gearbox 56 and the drum 14. Thiseliminates the need to have a separate bearing 66 for the gearbox 56 andthe drum 14. The bearing 66 supports any load placed on the drum 14while preventing such load from being placed on gears of the gearbox 56.This will ideally prevent wear, binding, or misalignment of the gears ofthe gearbox 56. In the illustrated embodiment, the motorized liftingdevice 10 has a bearing 66 at each end of the motorized lifting device10 to enable rotation of the drum 14. No additional bearings are neededfor the gearbox 56.

In certain embodiments in accordance with the invention, a short post 70may be incorporated onto the drum 14 or another rotating member for usewith an absolute position encoder 68, such as a resistive encoder 68.Such an encoder 68 may be used to measure a rotational angle of the drum14 relative to the rest of the motorized lifting device 10. The encoder68 may rotate with the post 70. Thus, in certain embodiments, the post70 may include a keyed shape (such as a “D” shape) that fits into acorresponding shape in the encoder 68. This fixes the encoder 68 to thedrum 14 and allows the encoder 68 to rotate with the drum 14. Theelectrical resistance of the encoder 68 may vary around itscircumference. A sensor measures the resistance of the encoder 68 as itrotates, thereby allowing the rotational angle of the encoder 68 anddrum 14 to be determined. The output of a resistive encoder 68 and themanner in which the output may be used to determine angular positionwill be discussed in association with FIGS. 35A and 35B.

In other embodiments, a magnetic encoder (not shown) may be used tomeasure a rotational angle of the drum 14. For example, the post 70 maybe replaced with a diametrically polarized magnet that rotates with thedrum 14. The magnet's rotational position may be monitored by a magneticresolver. Such an embodiment may be advantageous in that no mechanicalshaft may be required to turn a physical wiper, as may occur in aresistive encoder. Rather, the angular position may be magneticallycommunicated to a contactless sensor proximate thereto. Also, unlike aresistive encoder, a magnetic encoder may have no “dead band,” a conceptthat will be discussed in more detail in association with FIG. 35C. Inother embodiments, other types of absolute position encoders (e.g.,optical encoders, inductive encoders. etc.) may be used with theinvention. In yet other embodiments, a relative position encoder mayalso be used. For example, if position data (e.g., angular position,number of rotations, etc.) is regularly stored in non-volatile memory,the position data may be retrieved from the non-volatile memory after apower outage or other significant event. The relative position encodermay then be used to measure position relative to the retrieved positiondata.

Both the resistive and magnetic encoders are considered absoluteposition encoders 68. Most existing techniques for measuring angularposition utilize limit switches to indicate an end of travel and/or userelative position encoders. These techniques typically require acalibration point to establish a reference from which relative distancemay be calculated. This means that if power is interrupted, calibrationwill once again be required. Also, any movement that occurs while therelative encoder is powered down will not be detected with a relativeencoder. An absolute position encoder 68 differs from a relative encoderin that changes in angular position may be detected even when suchchanges occur during a power interruption.

Referring to FIGS. 14 through 16, several different views of a lockingmechanism 62 in accordance with the invention are illustrated. Aspreviously mentioned, in certain embodiments, a locking mechanism 62 maybe provided to prevent rotation of the drum 14, such as when themotorized lifting device 10 stops or shuts down due to a power outage oran overload condition. Such a locking mechanism 62 may be an importantsafety feature of the motorized lifting device 10, as well as enableother precision- and control-related features and functions of themotorized lifting device 10. In certain embodiments, the lockingmechanism 62 is locked by default, meaning that if the motorized liftingdevice 10 is powered down or not actively rotating the drum 14, thelocking mechanism 62 engages to prevent rotation of the drum 14.

In certain embodiments, the locking mechanism 62 may be configured tolock a shaft 74 of the motor 54 or a member 90 directly connected to theshaft of the motor 54. Because the motor 54 may have a much higher gearratio than the drum 14, locking the shaft 74 of the motor 54 may requireconsiderably less force than directly locking or stopping the drum 14.For example, if a single turn of the drum 14 requires six hundred andtwenty-five turns of the motor 54, then the amount of torque experiencedby the motor 54 will be 1/625^(th) of that experienced by the drum 14,assuming friction in the gearbox 56 and other locations is not takeninto consideration. As a result, locking the shaft 74 of the motor 54may be considerably easier than locking the drum 14 directly. Itsfollows that a considerably lighter device may be used to lock the shaft74 of the motor 54 than would be needed to directly lock or stop thedrum 14.

Thus, the locking mechanism 62 illustrated in FIGS. 14 through 16directly locks the shaft 74 of the motor 54 instead of locking orstopping the drum 14. As shown in FIG. 14, in one embodiment such alocking mechanism 62 may include an actuator 82 (e.g., solenoid) and alever 84 comprising a shaped aperture 86. The shaped aperture 86 may beconfigured to interface with and lock a shaped feature on the shaft 74,or a shaped feature on a component 90 connected to the shaft 74. Theactuator 82 may toggle the lever 84 between a first position that locksthe shaft 74 and a second position that unlocks the shaft 74. A pair ofarms 88 incorporated into the lever 84 may provide an axis along whichthe lever 84 pivots.

In the illustrated embodiment, a pair of flat surfaces are formed on acomponent 90 attached to the motor shaft 74. The shaped aperture 86 mayengage the flat surfaces to prevent rotation of the shaft 74, similar tothe way a wrench prevents rotation of a nut or bolt. In certainembodiments, the shaped aperture 86 may be made substantially largerthan the shaped feature 90 to provide some flexibility for the shapedaperture 86 to slide over the shaped feature 90, while still being smallenough to lock the shaped feature 90. To lock the shaft 74, the actuator82 moves the shaped aperture 86 over the shaped feature 90. To unlockthe shaft 74, the actuator 82 moves the shaped aperture 86 away from theshaped feature 90. FIG. 15 shows the position of the lever 84 when theshaft 74 is unlocked and FIG. 16 shows the position of the lever 84 whenthe shaft is locked.

Referring to FIGS. 17 through 22, another embodiment of a lockingmechanism 62 in accordance with the invention is illustrated. In thisembodiment, the locking mechanism 62 is positioned on the non-drivingend of the motor 54. In other words, a first end of the motor shaft 74may drive the gearbox 56 while the other end of the motor shaft 74 mayinterface with the locking mechanism 62. In other embodiments, thelocking mechanism 62 may be positioned on the driving end of the motor54.

In the illustrated embodiment, an actuator 82 moves a locking plate 92between a locked and unlocked position. The locking plate 92 includes anaperture 94 comprising a locking portion and an unlocking portion. Theaperture 94 may interface with a shaped feature 90 on or connected tothe shaft 74. When the locking plate 92 is moved to the locked position,the locking portion of the aperture 94 slides over the shaped feature 90to prevent rotation of the shaft 74. Similarly, when the locking plate92 is moved to the unlocked position, the unlocking portion of theaperture 94 slides over the shaped feature 90 to allow rotation of theshaft 74. As shown in the Figures, the locking plate 92 slides in aplane substantially perpendicular to the shaft 74.

FIG. 17 is a perspective view showing the locking mechanism 62 in anengaged (i.e., locked) position and FIG. 18 is a perspective viewshowing the locking mechanism 62 in a disengaged (i.e., unlocked)position. FIG. 19 is an end view showing the locking mechanism 62 in anengaged (i.e., locked) position and FIG. 20 is an end view showing thelocking mechanism 62 in a disengaged (i.e., unlocked) position. FIG. 21is an end view showing the position of the actuator 82 when the lockingmechanism 62 is in an engaged (i.e., locked) position and FIG. 20 is anend view showing the position of the actuator 82 when the lockingmechanism 62 is in a disengaged (i.e., unlocked) position.

Referring to FIGS. 23A through 24B, another embodiment of a lockingmechanism 62 in accordance with the invention is illustrated. Like theprevious embodiment, the locking mechanism 62 is positioned on thenon-driving end of the motor 54, although it may also potentially bepositioned on the driving end of the motor. In this embodiment, thelocking mechanism 62 includes an arm 96 comprising a locking feature102, such as gear teeth. This locking feature 102 may engage acorresponding locking feature 100 on the shaft 74, or a componentconnected to the shaft 74, such as gear teeth. An actuator 82 (e.g.,solenoid) may move the arm 96 to selectively engage and disengage thelocking features 100, 102. In the illustrated embodiment, the actuator82 combined with a pivoting linkage member 98 moves the arm toward theshaft 74 or away from the shaft 74, depending on the position of theactuator 82. FIG. 23A is a perspective view showing the lockingmechanism 62 with the shaft 74 locked and FIG. 23B is a perspective viewshowing the locking mechanism 62 with the shaft 74 unlocked. FIG. 24A isan end view showing the locking mechanism 62 with the shaft 74 lockedand FIG. 24B is an end view showing the locking mechanism 62 with theshaft 74 unlocked.

Referring to FIG. 25, another embodiment of a locking mechanism 62 inaccordance with the invention is illustrated. In this embodiment, thelocking mechanism 62 uses a rack 63 and pinion 65 to lock the shaft 74.Like the previous embodiment, the locking mechanism 62 is positioned onthe non-driving end of the motor 54, although it may also potentially bepositioned on the driving end of the motor 54. As shown, the lockingmechanism 62 includes an actuator 82 to move a rack 63 in a directionsubstantially perpendicular to the shaft 74. A pinion 65 is rigidlyattached to the shaft 74 and rotates with the shaft 74.

To disengage the locking mechanism 62, the actuator 82 withdraws therack 63 from the pinion 65 such that the teeth of the pinion 65 do notengage the teeth 67 of the rack 63. This allows the shaft 74 to spinfreely. To engage the locking mechanism 62, the actuator 82 releases therack 63 and a spring 69 urges the rack 63 toward the pinion 65. Thiscauses the teeth 67 of the rack 63 to engage and catch the teeth of thepinion 65. Rotation of the pinion 65 will pull the rack 63 into fullengagement with the pinion 65. When the actuator 82 is fully extended,the rack 63 will be unable move, thereby preventing rotation of thepinion 65 and shaft 74. In certain embodiments, the rack 63 may bebrought to a gradual stop with an elastic member (not shown) such as aspring, rubber stop, or shock absorber located at or near an end of therack 63 or incorporated into the actuator 82. This will soften anyimpact that occurs when the locking mechanism 62 engages. FIG. 26A showsa close-up view of the rack-and-pinion locking mechanism 62 whendisengaged and FIG. 26B shows a close-up view of the rack-and-pinionlocking mechanism 62 when engaged.

In certain embodiments, an additional braking mechanism may be providedto assist the locking mechanisms 62 illustrated in FIG. 14 through 26B.In certain cases, a locking mechanism 62 may have trouble engaging ormay be subject to excessive wear and tear if the motor 54 is spinningtoo fast when the locking mechanism 62 tries to engage. The additionalbraking mechanism may slow the motor 54 sufficiently for the lockingmechanism 62 to engage as well as prevent wear and tear on the lockingmechanism 62.

In one embodiment, the additional braking mechanism is provided byautomatically shorting the motor leads when the motor is stopped orpower is interrupted. With a DC motor 54, shorting the motor leads maycause the motor 54 to act as a generator, thereby causing the motor 54to resist rotation. The motor 54 will ideally slow down enough for thelocking mechanism 62 to engage. In certain embodiments, the motor leadsare shorted with a relay 182 that automatically closes when the motor 54stops or power is interrupted, as shown in FIG. 38.

In other embodiments, an energy storage device such as a battery orcapacitor may be used as a braking mechanism. When power to themotorized lifting device 10 is interrupted, the energy storage devicemay power the motor 54 in a direction opposite the direction ofrotation, thereby slowing the motor 54 sufficiently to engage thelocking mechanism 62. An energy storage device having suitable storagecapacity and power density may be selected to provide the desiredbraking function long enough for the locking mechanism 62 to engage. Incertain embodiments, the energy storage device may also providetemporary power to other electronics to enable an orderly shut down ofthe motorized lifting device 10. For example, electronics (such as thelogistics electronics previously discussed) may be powered for longenough to store a current position of the end of the line 16 or otherinformation that may be helpful or required when power is restored.

Referring to FIG. 27, as previously mentioned, the motorized liftingdevice 10 may be configured to lift or lower a load, up to the weightrating of the device. Various controls may be provided with themotorized lifting device 10 to enable a user to lift or lower the load.For example, the controls may provide a “lift” and “lower” button thatwhen pressed causes an end of the line 16 to go up and downrespectively. Such controls may provide fairly rudimentary operation ofthe motorized lifting device 10.

In certain cases, it may be desirable for the motorized lifting device10 to function in a more intelligent manner. For example, it may bedesirable to establish various set points for the motorized liftingdevice 10 and have the motorized lifting device 10 automatically stop atthese set points as it lifts or lowers a load. For example, referring toFIG. 27, a user may establish the following set points: High Stop,Intermediate Stop 1, Intermediate Stop 2, and Low Stop. In certainembodiments, the user may establish the set points by raising orlowering the line 16 and selecting an option to store or remember theposition of the line 16 at each stop. Once the set points areestablished, a user may press a “smart lift” or “smart lower” button tocause the motorized lifting device 10 to raise or lower the line 16 tothe next set point, without requiring the user to hold down the buttonor be present. Such a feature may be useful to intelligently lift orlower a wide variety of loads with just a touch of a button.

For example, referring to FIG. 28, if the motorized lifting device 10 ismounted to a ceiling and used to lift or lower a bicycle from theceiling, a user may desire to establish the set points illustrated inFIG. 28. A first set point (i.e., High Set Point) may raise the bicycle104 close to the ceiling and a second set point (i.e., Low Set Point)may lower the bicycle 104 to a point at or near a floor where thebicycle may be easily released from the line 16, as well as allow thebicycle 104 to be re-attached to the line 16 when it is ready to beraised back up. The user may establish the set points by raising orlowering the bicycle to desired points and selecting the option to storeor remember the position of bicycle. Once the set points areestablished, a user may press a “smart lift” or “smart lower” button toraise or lower the bicycle to the established set points withoutrequiring the user to hold down the buttons.

Referring to FIG. 29, one embodiment of a controller 106 for performingthe functions described in association with FIGS. 27 and 28 isillustrated. In this example, such a controller 106 is embodied as anapplication executing on a mobile general-purpose processing device 108,such as a smart phone, tablet, or laptop. As shown in FIG. 29, incertain embodiments, the application may include a user interface 110providing various controls. Such a user interface 110 may take on manyforms and thus is presented by way of example and not limitation. Itshould be recognized that the user interface 110 may include otherpages, windows, menus, or the like, and thus is not intended to reflectthe complete functionality of the application. Other possible featuresor functions of the application are described in more detail inassociation with FIG. 40. It should also be recognized that althoughcertain features and functions are shown on the user interface 110, suchfunctions and features could easily be distributed across multiplepages, windows, or menus of a user interface 110.

As shown in FIG. 29, in certain embodiments, the user interface 110 mayinclude one or more of the following virtual buttons for operation by auser: a “lift” button 112, a “lower” button 114, and a “stop” button116. Pressing the “lift” button 112 may cause the motorized liftingdevice 10 to raise the line 16 until the button is released or until theline 16 reaches an upper limit or stop point. Similarly, pressing the“lower” button 114 may cause the motorized lifting device 10 to lowerthe line 16 until the button is released or the line 16 reaches a lowerlimit or stop point. Pressing the “stop” button 116 may cause themotorized lifting device 10 to stop. In certain embodiments, stoppingthe motorized lifting device 10 may include engaging the lockingmechanism 62 previously discussed. Similarly, either raising or loweringthe line 16 may cause the locking mechanism 62 to disengage.

The user interface 110 may also include buttons that enable themotorized lifting device 10 to function in a more intelligent manner.For example, the user interface 110 may enable a user to establishvarious set points for the motorized lifting device 10 and have themotorized lifting device 10 automatically stop at these set points as itlifts or lowers a load. For example, a “set low” button 118 mayestablish a low set point at a current location of the line 16.Similarly, a “set high” button 120 may establish a high set point at acurrent location of the line 16. The high set point and low set pointmay be stored in non-volatile memory (such as memory of the processingdevice 108 or in memory of the motorized lifting device 10) for use at alater time.

A “smart lower” button 122 may cause the motorized lifting device 10 tolower the line 16 until it reaches the low set point and a “smart lift”button 124 may cause the motorized lifting device 10 to raise the line16 until it reaches the high set point. In other embodiments, the userinterface 110 may enable a user to establish other intermediate setpoints in addition to the high and low set points. Unlike the “lift”button 112 and the “lower” button 114, a user may not be required tohold down the “smart lower” button 122 or “smart lift” button 124 toperform the associated functions.

Referring to FIG. 30, in other embodiments, a controller 106 inaccordance with the invention may take the form of a dedicatedcontroller 106. Such a dedicated controller 106 may contain hardware andfirmware dedicated to controlling the motorized lifting device 10. Inthis embodiment, the controller 106 includes a display 126 and variousphysical buttons. In certain embodiments, physical buttons such as a“lift” button 112, “lower” button 114, “stop” button 116, “smart lower”button 122, and “smart lift” button 124 may be provided. Other physicalbuttons such as arrow buttons and a “select” button may enable a user tonavigate the display 126 and select particular options or items. Any ofthe physical buttons may be implemented as virtual buttons, such asbuttons on a touch screen. As shown on the display 126 of FIG. 30,particular motorized lifting devices 10 may be assigned names, such as“kayak” or “bike”, depending on the type of load that is being lifted.These names may be combined with possible actions to enable the user toquickly select the action he or she wants to perform. For example, inthe illustrated embodiment, the display 126 provides a “kayak lift” and“bike lift” option. Selecting these options may cause the motorizedlifting device 10 to lift the object to a high set point established forthese objects. The dedicated controller 106 is presented by way ofexample and not limitation. Other features and functions for thededicated controller 106 are possible and within the scope of theinvention.

Referring to FIG. 31, in certain embodiments, it may be desirable tohave multiple motorized lifting devices 10 operate in a synchronizedmanner. For example, multiple motorized lifting devices 10 a-d may beconfigured to lift a shared load, such as the illustrated platform 126.When using multiple synchronizing motorized lifting devices 10 to lift ashared load, apparatus and methods are needed to ensure that themotorized lifting devices 10 stay synchronized. For example, if onemotorized lifting device 10 were to stop while the other motorizedlifting devices 10 continued lifting or lowering a load, the platform126 could tip, potentially spilling items or creating a safety hazard. Asimilar situation could occur if some motorized lifting devices 10 wereto move faster or slower than others. For example, if a load weredistributed unevenly among the motorized lifting devices 10, this couldcause some motorized lifting devices 10 to move faster or slower thanothers, potentially causing the platform 126 to tip. Apparatus andmethods are needed to detect such conditions and make speed or positionadjustments where needed to ensure that the motorized lifting devices 10stay synchronized with one another.

As will be explained in more detail hereafter, in certain embodiments agrouping module may be used to group motorized lifting devices 10 forsynchronized operation and a synchronization module may be used to keepthe group of motorized lifting devices 10 synchronized with one another.Once grouped, the motorized lifting devices 10 may be operated as ifthey were a single device. For example, a single button press on thecontroller 106 may cause all of the motorized lifting devices 10 in thegroup to operate in a synchronized manner, such as by lifting orlowering a load.

In certain embodiments, the grouping module and synchronization modulemay be implemented in the controller 106 previously discussed. In otherembodiments, the grouping module or synchronization module may beimplemented in the motorized lifting devices 10 or distributed betweenthe controller 106 and the motorized lifting devices 10. In general, thesynchronization module may monitor operating parameters (position of theline, speed, etc) of the motorized lifting devices 10 in the group andadjust the operating parameters to keep the motorized lifting devices 10substantially synchronized.

In certain embodiments, a synchronization module in accordance with theinvention may be configured to identify a slowest moving motorizedlifting device 10 in a group and then adjust the other motorized liftingdevices 10 in the group to keep pace with the slowest motorized liftingdevice 10. For example, if a group of motorized lifting devices 10 islifting a shared load and the synchronization module detects (byrequesting or periodically receiving data, etc.) that one of themotorized lifting devices 10 in the group is lifting or lowering theload slower than the others (due, for example, to supporting more weightthan the other motorized lifting devices 10), the synchronization modulemay adjust (by sending commands, etc.) the speed of the other motorizedlifting devices 10 to match the speed of the slowest motorized liftingdevice 10. Similarly, if the synchronization module detects that anamount of line 16 let out from each of the motorized lifting devices 10is causing a tilted platform 126, the synchronization module may adjustthe amount of line 16 let out from each of the motorized lifting devices10 to level out the platform 126. Similarly, if the synchronizationmodule detects that one of the motorized lifting devices 10 has stopped(due, for example, to a power outage or an overload condition) or lossof communication, the synchronization module may cause the othermotorized lifting devices 10 to stop to maintain a level platform 126 orprevent safety hazards. In certain embodiments, a loss of communicationbetween a controller and any motorized lifting device 10 mayautomatically cause the motorized lifting device 10 to stop, sinceoperating parameters of the motorized lifting device 10 may no longer bemonitored.

Referring to FIG. 32, in certain embodiments, when several motorizedlifting devices 10 are grouped for synchronized operation, it may bedesirable to more optimally distribute a load between the motorizedlifting devices 10. As mentioned above, a poorly distributed load maycause one or more of the motorized lifting devices 10 to be overloaded(causing a shutdown) or cause certain motorized lifting devices 10 tooperate slower than others. FIG. 32 shows an example where a shared loadis unequally distributed between a pair of motorized lifting devices 10a, 10 b. Specifically, a ten pound weight is located near the motorizedlifting device 10 a and a twenty-five pound weight is located near themotorized lifting device 10 b.

In certain embodiments, the application discussed in association withFIG. 29 may be configured to assist a user in more optimally placing theload. For example, in one embodiment, the user interface 110 may includea gauge 128 for each motorized lifting device 10 in the group, whereeach gauge 128 indicates an amount of weight supported by the motorizedlifting device 10. In certain embodiments, the gauge 128 may use colorsto indicate an amount of weight (e.g., color going from green to red asthe amount of weight increases). Using this information, the user mayrearrange weights on the platform 126 to more equally distribute theweight among the motorized lifting devices 10 a, 10 b. In other or thesame embodiments, the application may be configured to suggest how toredistribute weight among the motorized lifting devices 10. For example,based on the measured weight values, the application may suggest to“move weight toward motorized lifting device X” or “reduce weight onmotorized lifting device X” to more equally distribute the weight.

Referring to FIG. 33, in certain embodiments, a mounting bracket 130 maybe provided to enable quick and easy mounting/dismounting of themotorized lifting device 10 to a wall, ceiling, or other structure. FIG.33 shows a short mounting bracket 130 a that may be mounted to a wall,ceiling, or other structure. The motorized lifting device 10 may bequickly attached to the mounting bracket 130 a with pins, bolts, orother fasteners. FIG. 9 shows a motorized lifting device 10 mounted to abracket like that illustrated in FIG. 33 with removable pins. FIG. 33shows a longer mounting bracket 130 b that may be mounted to a wall,ceiling, or structure. The longer bracket 130 b is advantageous in thata motorized lifting device 10 may be moved to a desired position alongthe bracket 130 b, or multiple motorized lifting devices 10 may besimultaneously mounted to the bracket 130 b at different locations. Thelonger bracket 130 b may also be advantageous in that the bracket 130 bmay be mounted to a stud, joist, or structural member, or across severalstuds, joists, or structural members, allowing the motorized liftingdevice 10 to be mounted to the bracket 130 b at points in between. Thus,the longer bracket 130 b may provide greater flexibility as to where tomount the motorized lifting device 10.

Referring to FIG. 34, one important feature of the motorized liftingdevice 10 is its ability to determine the weight of an object 136attached to the line 16. The disclosed motorized lifting device 10 mayaccomplish this by monitoring lifting speed as well as power consumed bythe motor 54. Lifting speed may be measured by calculating a change inposition (using the encoder 68) divided by time. Power consumed by themotor 54 may be measured with a voltage/current sensor 134. Aspreviously mentioned, the grooved drum 14 and single layer of line 16help to ensure that the line 16 maintains a constant radius throughoutthe wind.

The weight of the object 136 creates a back torque on the motor 54through the drum 14 and gearbox 56. The amount of power consumed(measured by the voltage/current sensor 134) and the speed of the motor54 (determined with the encoder 68) vary in accordance with the amountof torque required to lift the object 136. Thus, the amount of powerconsumed (minus any power consumed by the motorized lifting device 10absent weight on the line 16) as well as the speed of the motor 54 maybe used to calculate the amount of torque. The torque will generallyremain constant as long as the weight and radius remain constant. Theamount of torque and radius may be used to calculate the amount ofweight attached to the end of the line 16. For a group of motorizedlifting devices 10 lifting a shared load, the weight of the shared loadmay be calculated by summing the individual weights calculated for eachmotorized lifting device 10.

Once the weight of an object is known, it may be used for variouspurposes, including reporting the weight back to a monitoring device(such as the controller 106), or setting thresholds of operation causingthe motorized lifting device 10 to shut down or stop if a weight limitis exceeded. More advanced uses may include monitoring changes in theload, and causing the motorized lifting device 10 to perform variousautomated responses, such as stopping, reversing direction, or reportingerrors, if the load changes by more than a specified amount. Forexample, if the motorized lifting device 10 detects that little or noload is supported by the line 16 for a specified time period, themotorized lifting device 10 may raise the line 16 up to a high set pointto prevent safety issues associated with dangling or stray lines 16.

In other cases, a significant or sudden decrease in load may indicatethat an object 136 has detached from the line 16 or has come to rest onanother object, which may in turn trigger an automated response (e.g.,raising up the line 16). Similarly, a significant or sudden increase inthe load may indicate that the line 16 has undesirably caught on anotherobject, become tangled, or the like, which may also trigger an automatedresponse. The weight measurement may also be helpful to more optimallydistribute a shared load across multiple motorized lifting devices 10,as previously discussed. For example, each motorized lifting device 10in a group may report weight back to a controller 106, which may thenprovide feedback to a user in the form of weight values or suggestionshow to more optimally distribute the load.

Referring to FIGS. 35A through 35C, as previously mentioned, an absoluteposition encoder 68 may be used to measure an angular position of thedrum 14 without calibration, even after power interruptions. A countermay keep track of a number of rotations of the drum 14 and store thisinformation in non-volatile memory. This information (i.e., the angularposition and the number of rotations) may enable the motorized liftingdevice 10 to precisely and quickly determine how much line 16 is let outfrom the drum 14, even after a significant event such as a power outage.

As previously mentioned, various different types of absolute positionencoders 68 may be used to determine the angular position of the drum14. The type of absolute position encoder 68 used and the way it isimplemented may be based at least partly on the type of output itproduces. FIG. 35A shows an output from a resistive absolute positionencoder 68 over several revolutions. FIG. 35C shows an output from amagnetic absolute position encoder 68 over several revolutions.

A resistive rotary encoder 68 may produce an absolute analog value overa revolution. As previously mentioned, in one embodiment, the encoder 68may be coupled to a post 70 incorporated into the drum 14 in order tomonitor angular position. In some resistive encoders 68, a shaft movesan internal wiper of the encoder 68 which in turn changes an analogvalue output from the encoder. The resistive encoder 68 may produce anoutput that is characterized by a “dead spot” or “dead band”. This “deadspot” or “dead band” may reflect a portion of the rotation where theinternal wiper is no longer connected to an internal resistive element.The waveform 138 (FIG. 35A) represents the output from the resistiveencoder 68 over one revolution. As shown, the waveform 138 includes adead band 140 which produces no analog output.

In certain embodiments, any drawbacks of the dead band 140 of theresistive encoder 68 may be mitigated by using a pair of resistiveencoders 68 offset by some angle to prevent overlapping of their deadbands 140, such as is illustrated in FIG. 35B. The dotted linerepresents the output from the additional resistive encoder 68. Asshown, the dead bands from the two encoders do not overlap. The outputfrom the additional resistive encoder 68 may be monitored while theother resistive encoder 68 is passing through its dead band, and viceversa.

In other embodiments, a magnetic encoder 68 may be used as the absoluteposition encoder 68. In such embodiments, the short post 70 may bereplaced with a diametrically polarized magnet that rotates with thedrum 14. The magnet's rotational position may be monitored by a magneticresolver mounted proximate the polarized magnet. Such an embodiment maybe advantageous in that no mechanical shaft may be required to turn aphysical wiper, as may occur in a resistive encoder. This eliminateswear and tear caused by rubbing parts. Rather, the angular position maybe magnetically coupled to a sensor with no contact required. Also,unlike a resistive encoder, a magnetic encoder may have no “dead band,”as shown in FIG. 35C.

Referring to FIGS. 36A through 36D, in certain embodiments in accordancewith the invention, it may be advantageous to convey power and/or datato or from an object (e.g., a tool, electromagnet, camera, transducer,battery, sensor, etc.) attached to an end of the line 16. For example,if a power tool is attached to the end of the line 16, power and/orcontrol signals may need to be conveyed to the power tool. If a sensoris attached to the end of the line 16, power may be provided to thesensor and data may be gathered from the sensor. In some embodiments,power may be provided to an electrical receptacle at the end of the line16. Other possible scenarios where it may be desirable to convey powerand/or data to or from an object at the end of the line 16 are possibleand within the scope of the invention.

In certain embodiments in accordance with the invention, a transmissioncable for conveying power and/or data may be incorporated into the line16. This transmission cable may be configured to support all or part ofa load at the end of the line 16. Thus, the transmission cable may beara load in addition to transporting power and/or data. In otherembodiments, the transmission cable is non-load-bearing, meaning that aseparate load-bearing cable or wire may also be incorporated into theline 16. In other embodiments, the transmission cable bears a portion ofthe load, while another cable bears the rest of the load. The cables maybe encased in rubber, plastic, or other insulating materials toelectrically isolate the cables from one another, protect the cablesfrom damage, as well as prevent shorting with other objects.

In certain embodiments, multiple transmission cables may be incorporatedinto the line 16. For example, separate power and data cables may beincorporated into the line 16, or possibly multiple power cables ormultiple data cables, depending on the application involved. Thetransmission cables may be fully load-bearing, partially load-bearing ornon-load-bearing as previously described. In certain embodiments, aseparate load-bearing cable or wire may be used alongside thetransmission cables.

Because the line 16 may support a load in addition to providing powerand/or data to objects at the end of the line 16, a connector may beneeded that can both convey power and/or data as well as support a load.FIGS. 36A through 36D show several views of a connector 142 that mayperform both functions. As can be seen in the Figures, the connector 142may include an interlocking plug 144 and socket 146. In this embodiment,the plug 144 is connected to the line 16 and the socket 146 wouldconnect to an object. FIG. 36A shows the plug 144 and socket 146interlocked with one another. FIG. 36B shows the plug 144 and socket 146disconnected from one another. FIG. 36C shows an exploded view of thesocket 146 and FIG. 36D shows an exploded view of the plug 144.

As can be observed in FIGS. 36A and 36B, the line 16 is firmly connectedto the plug 144 to provide load-bearing capabilities. In thisembodiment, the socket 146 includes a hook-shaped slot 148 configured toreceive a pin 150 of the plug 144. To connect the plug 144 to the socket146, the plug 144 may be inserted into the socket 146, pushed down tocompress a spring 152 or other biasing member 152, and twisted andreleased so that the pin 150 becomes confined in the hook-shaped slot148. The spring 152 may take up slack between the plug 144 and socket146 to ensure that the plug 144 and socket 146 stay connected to oneanother. Disconnecting the plug 144 and socket 146 may be the same asconnecting the components, except that the components may be twisted inthe opposite direction.

FIG. 36C shows a socket 146 that includes a platform 154 comprisingthree pins, a spring 152 urging the platform 154 in an upward direction,and a base 156 to connect the socket 146 to an object. Power and/or datacables (not shown) may connect to the pins of the platform 154. FIG. 36Dshows a plug 144 comprising a three-hole receptacle 158, mounted to abody 160, to mate with the pins of the platform 154. The pin 150 forinterlocking with the socket 146 is also shown. Power and/or data cables(not shown) incorporated into the line 16 connect to contacts within theholes of the three-hole receptacle 158.

Referring to FIGS. 37A and 37B, another embodiment of a connector 142 isillustrated. In this embodiment, the connector 142 includes a plug 144configured to slide into a socket 146 in a direction substantiallyperpendicular to a direction applied by a load. FIG. 37A shows the plug144 and socket 146 interlocked with one another. FIG. 37B shows the plug144 and socket 146 disconnected from one another.

As shown, the plug 144 includes a broad base portion 162 and a narrowerupper portion 164. The broad base portion 162 may snap into the socket146 to bring electrical contacts of the plug 144 into contact withelectrical contacts of the socket 146. A release button 168 may retainthe plug 144 within the socket 146. Pressing the release button 168 mayrelease the plug 144 from the socket 146. The design of the connector142 may prevent the load from being exerted on the release button 168.Rather, a pair of flanges 166 on the socket 146 may retain the broadbase portion 162 of the plug 144 and support most if not all of the loadplaced on the connector 142.

Referring to FIG. 38, a high-level view showing various electronichardware components that may be used in a motorized lifting device 10 inaccordance with the invention is illustrated. As previously discussed,in order to avoid interference between various electronic components, incertain embodiments logistics electronics 170 may be mounted proximate afirst end of the motorized lifting device 10 and power electronics 172may be mounted proximate a second end of the motorized lifting device10.

In general, the logistics electronics 170 may include lower powerelectronics such as a communication module 176 to enable data andcommands (i.e., communication signals 190) to be communicated to themotorized lifting device 10 from external devices, data processingelectronics such as a microcontroller 174, an encoder 68 for measuringan angular position of the drum, and non-volatile memory 178 for storingdata. A communication module 176 may include, for example, a Bluetoothcontroller 176 for receiving wireless Bluetooth communications fromexternal devices, such as an external controller 106, to control themotorized lifting device 10. Other types of communication modules 176,such as WIFI modules, Zigbee modules, or the like, may also be used toenable communication with the motorized lifting device 10.

Among other functions, the microcontroller 174 may be used to processdata and commands received from devices such as the controller 106,encoder 68, voltage/current sensor 134, temperature sensor 184, or thelike, and generate appropriate control signals 186 to control the motor54 or other devices. For example, the microcontroller 174 may receivecommands from a remote control 106 to lift, lower, or stop the line 16,and execute the commands by sending appropriate control signals 186 tothe motor 54. The microcontroller 174 may also receive commands to liftor lower the line 16 to a pre-established set point, and execute thecommands by sending appropriate control signals 186 to the motor 54.Using inputs from the encoder 68, the microcontroller 174 may keep trackof the angular position of the drum 14, the number of rotations of thedrum 14, as well as the current position of the end of the line 16. Themicrocontroller 174 may also monitor the voltage/current sensor 134 ortemperature sensor 184 to prevent overloading or overheating. Usinginputs from the voltage/current sensor 134 and encoder 68, themicrocontroller 174 may calculate operating parameters such as theweight of a load attached to the line 16. These represent just a fewfunctions that may be performed by the microcontroller 174. Otherfeatures and functions performed by the microcontroller 174 or othercomponents will be discussed in association with FIGS. 39 and 40.

In general, power electronics 172 may include higher power electronicsto receive power 192 and drive the motor 54. Such power electronics 172may include, for example, a motor driver 180 to drive the motor 54, arelay 182 for shorting terminals of the motor 54 when the drum 14 stopsor when power is interrupted, a voltage/current sensor 134 for sensingvoltage or current to the motor 54, or a temperature sensor 184 forsensing a temperature of the motor 54. Placing the logistics electronics170 and power electronics 172 on separate ends of the motorized liftingdevice 10 may prevent noise or other signals generated by the powerelectronics 172 from interfering with operation of the more sensitivelogistics electronics 170. As previously discussed, a power and/or datacable 24, such as a ribbon cable 24, may be routed across a top of themotorized lifting device 10 to enable power and/or data 188 to becommunicated between the logistics electronics 170 and the powerelectronics 172.

Referring to FIG. 39, a more particular view of the microcontroller 174described in FIG. 38 is illustrated. Various blocks are shown within themicrocontroller 174 to provide a better understanding of variousfeatures or functions that may be provided by the microcontroller 174.The blocks may be implemented in hardware, firmware, or a combinationthereof. Arrows have also been drawn between the blocks to show possiblecommunication between blocks. The blocks and arrows are provided by wayof example and should not be interpreted as indicating the complete setof functions or communications that may occur within the microcontroller174. In other embodiments, certain functions and communications shown inthe microcontroller 174 may be implemented on different hardwarecomponents or even distributed across multiple hardware components. Forexample, the non-volatile memory 178 illustrated in FIG. 39 may beimplemented within the microcontroller 174 or as a device separate fromthe microcontroller 174.

As shown in FIG. 39, in certain embodiments, the microcontroller 174 mayinclude one or more of a communication interface 194, a main application196, a servo control module 198, a modulation module 200, a positiontracking module 202, and non-volatile memory 178. A communicationinterface 194 may allow the microcontroller 174 to communicate (i.e.,send or receive data or commands) with a remote control 106 by way ofthe communication module 176 previously discussed. The main application196 may perform a wide variety of features and functions, the likes ofwhich will be discussed in more detail hereafter through the use ofvarious examples. Among other duties, the main application 196 maycoordinate the activities of other modules or components inside oroutside the microcontroller 174.

The servo control module 198 may generate an error signal based on adifference between a current position of the end of the line 16 and adesired position for the end of the line 16. Based on this error signal,a modulation module 200 may produce a control signal using a suitablemodulation technique (e.g., pulse-width modulation, or PWM). Thismodulated control signal may be sent to the motor driver 180 to controlthe motor 54 with the intention of bringing the current position of theend of the line 16 closer to the desired position for the end of theline 16. The servo control module 198 may continually monitor thedifference between the current position of the end of the line 16 andthe desired position for the end of the line 16 and adjust the errorsignal accordingly.

A position tracking module 202 may monitor the current position of theend of the line 16. This may be accomplished by keeping track of theangular position of the drum 14 (received from the encoder 68) and thenumber of rotations of the drum (using a counter). In certainembodiments, the current position data 206 may be stored in non-volatilememory 178 so that if a power outage were to occur, the motorizedlifting device 10 could immediately determine the current position ofthe end of the line 16 by reading the position data 206.

As indicated above, operation of the main application 196 andmicrocontroller 174 may be best understood through various examples.Assume, for example, that a user wishes to establish a low set pointbased on the current position of the end of the line 16. To accomplishthis, the user may press the “set low” button 118 on the controller 106.In response, the controller 106 may generate an appropriate command(such as a “set low” command) and send this command to themicrocontroller 174 by way of the communication module 176. Uponreceiving this command through the communication interface 194, the mainapplication 196 may identify the command as a “set low” command andexecute the command. Executing the command may include determining thecurrent position of the end of the line 16 by querying the positiontracking module 202 (or reading the position data 206 in thenon-volatile memory 178), and then setting the low set point to equalthe current end of the line 16. The low set point may be recorded in thenon-volatile memory 178 for retrieval at a later time.

Assume now that the current end of the line 16 is raised above the lowset point and that the user wants the end of the line 16 to go to thelow set point. To accomplish this, the user may press the “smart lower”button 122 on the controller 106. In response, the controller 106 maygenerate a “smart lower” command and send this command to the mainapplication 196 by way of the communication module 176 and communicationinterface 194. Upon receiving the command, the main application 196 mayidentify the command as a “smart lower” command and execute the command.Executing the command may include retrieving the low set point 204 fromthe non-volatile memory 178 and determining a current position of theend of the line 16. Control may then be passed to the servo controlmodule 198 to generate an error signal based on the difference betweenthe position associated with the low set point and the current positionof the end of the line 16. The modulation module 200 may receive theerror signal and generate a control signal for controlling the motor 54.As line is let out from the motorized lifting device 10, the servocontrol module 198 continually monitors the difference between thecurrent position of the end of the line 16 and the desired position forthe end of the line 16 and adjusts the error signal accordingly. Thespeed of the motor 54 and position of the line 16 may be continuallyadjusted until the error signal reaches zero. When the error signalreaches zero, the current end of the line 16 will be at the positionassociated with the low set point.

In another example, the main application 196 may continually monitor theweight at the end of the line 16. The main application 196 mayaccomplish this by monitoring the power consumed by the motor 54 (usingthe voltage/current sensor 134) and the speed of the motor 54 (using theposition tracking module 202). If the weight exceeds the rating of themotorized lifting device 10, the main application 196 may shut off themotorized lifting device 10, such as by cutting off power to the motor54. In certain embodiments, the weight may be periodically reported tothe controller 106 for presentation to a user. Like weight monitoring,the main application 196 may also monitor the temperature of the motor54 (using the temperature sensor 184) and shut off the motorized liftingdevice 10 if the temperature exceeds a specified value. Shutting off themotor 54 may cause the locking mechanism 62 to engage and preventrotation of the drum 14.

In other examples, the main application 196 may receive and executeother types of commands from the controller 106. For example, a user maypress the lift, lower, or stop buttons 112, 114, 116 on the controller106. Each of these buttons may cause a different command to be generatedand sent to the microcontroller 174. Upon receiving these commands, themain application 196 may execute the commands by sending appropriatecontrol signals to the motor 54 to lift, lower, or stop the motor 54.Other types of commands are also possible and within the scope of theinvention. In general, the main application 196 may receive commandsfrom the controller 106 and execute the commands on the motorizedlifting device 10.

Referring to FIG. 40, one embodiment of an application 210 forimplementation on a controller 106 is illustrated. Such an application210 may include one or more modules for implementing various features orfunctions. Such modules may be implemented in hardware, software, or acombination thereof. It should be recognize that although such modulesare shown to be implemented in an application 210 hosted on thecontroller 106, the modules are not necessary implemented on thecontroller 106 or entirely on the controller 106. For example, certainfunctionality in the controller 106 may have corresponding functionalityin the motorized lifting device 10. For example, functionality forgenerating commands (e.g., lift, lower, stop commands) at the controller106 may have corresponding functionality for executing the commands atthe motorized lifting device 10.

In other cases, a motorized lifting device 10 may be configured to actas a controller 106. For example, if several motorized lifting devices10 are configured to operate in a synchronized manner, one motorizedlifting device 10 from the group may be configured to act as a master,while other motorized lifting devices 10 may be configured to act asslaves. In such cases, certain functionality may be implemented in themaster while other functionality is implemented in the slaves. Forexample, a master may include functionality to generate commands whilethe slaves may include functionality to execute the commands from themaster. Thus, a motorized lifting device 10 may, in certain embodiments,be configured with functionality shown in the controller 106. Thus,although shown in the controller 106, the illustrated modules may bedistributed across multiple devices or in some cases implemented ondevices other than the controller 106.

As shown in FIG. 40, in certain embodiments, an application 210 inaccordance with the invention may present a device list 212 to a user.This device list 212 may display individual devices 214 (i.e.,individual motorized lifting devices 10 configured for independentoperation), and grouped devices 216 (groups of motorized lifting devices10 configured for synchronized operation). As can be appreciated, incertain embodiments a user may own or use multiple motorized liftingdevices 10, with some being configured for independent operation andothers being configured for grouped (i.e., synchronized) operation. Thedevice list 212 may help the user manage the individual or groupedmotorized lifting devices 10 that he or she uses or owns.

A selection module 218 may enable a user to select an individual device214 or grouped device 216 from the device list 212 in order to performdesired operations. For example, a user may select an individual device214 from the device list 212 and perform lift, lower, stop, set low, sethigh, smart lift, or smart lower operations on the individual device214. Similarly, the user may select a grouped device 216 from the devicelist 212 and perform lift, lower, stop, set low, set high, smart lift,or smart lower operations on the grouped device 216. The motorizedlifting devices 10 associated with the grouped device 216 may thenoperate in a seamless synchronized manner as if the grouped motorizedlifting devices 10 were a single device.

A discovery module 220 may enable a user to discover new devices so thatthey may be added to the device list 212. Discovery may be needed, forexample, when initially setting up one or more motorized lifting devices10. Similarly, if a user adds a new motorized lifting device 10 to analready existing collection of motorized lifting devices 10, thediscovery module 220 may discover (i.e. detect, such as wirelesslydetect) the addition of the new motorized lifting device 10 so that themotorized lifting device 10 can be added to the device list 212.Techniques for wireless discovery, such as are commonly used withBluetooth devices, WIFI devices, or the like, may be used by thediscovery module 220, depending on the communication protocol used. Incertain embodiments, a communication protocol is selected that providessecure communication between the application 210 and the user's devices,ensuring that unauthorized users are not able to gain control.

Once devices are discovered by the discovery module 220, an adddevice/group module 222 may enable a user to add a device or group tothe device list 212. Similarly, a delete device/group module 224 mayenable a user to delete a device or group from the device list 212. Oncea device or group is added to the device list 212 or alternatively auser selects a device or group from the device list 212, a connectionmodule 226 may establish a connection with the device or group. Thiswill enable data and commands to be communicated between the controller106 and the device or group. For example, if a Bluetooth communicationprotocol is used, pairing procedures of the Bluetooth protocol may befollowed to establish connections with devices or groups in the list212.

In certain embodiments, a naming module 228 may enable a user to namedevices or groups of devices in the device list 212. This may help theuser to distinguish between devices and groups in the device list 212.For example, if a motorized lifting device 10 is used to lift a bicycle,the motorized lifting device 10 may be named “bike lift” in the devicelist 212. Similarly, if a group of motorized lifting devices 10 is usedto lift a platform holding holiday decorations, the group may be named“holiday decoration lift.” In certain embodiments, the naming module 228may be configured to assign default names (e.g., “lift 1”, “lift 2”,“group 1”, “group 2”) to devices or groups in the event names are notassigned by a user.

As previously discussed in association with FIG. 29, in certainembodiments an application 210 in accordance with the invention mayprovide one or more of a lift button 112, lower button 114, and a stopbutton 116. A lift module 230, lower module 232, and stop module 234 maybe provided to implement the functionality of these buttons. In general,when one of these buttons is pressed, a command may be generated at thecontroller 106 and sent to a motorized lifting device 10 or group ofmotorized lifting devices 10 for execution thereon.

A set point module 236 may enable a user to establish various set pointsfor the end of the line 16. For example, when a user presses thepreviously discussed “set low” button 118 or “set high” button 120, theset point module 236 may cause a low or high set point to be establishedand stored in non-volatile memory 178. The set point module 236 may incertain embodiments also enable a user to establish and storeintermediate set points between the low set point and high set point.When a “smart lower” button 122 is pressed, a smart lower module 240 maycause a low set point (or a next set point lower than a current positionof the end of the line 16) to be retrieved from memory 178 and cause amotorized lifting device 10 or group of motorized lifting devices 10 tolower the end of the line 16 to the set point. Similarly, when a “smartlift” button 124 is pressed, a smart lift module 238 may cause a highset point (or a next set point higher than a current position of the endof the line 16) to be retrieved from memory 178 and cause the motorizedlifting device 10 or group of motorized lifting devices 10 to raise theend of the line 16 to the set point.

In certain embodiments, the application 210 includes a weight module 242to determine an amount of weight lifted by a motorized lifting device 10or group of motorized lifting devices 10. In certain embodiments, theweight may be calculated from the amount of power consumed by the motor54 and/or the speed of the motor 54 when lifting an object. In certainembodiments, the weight module 242 may display the weight value to auser, thereby allowing the user to make adjustments where needed. Amongother benefits, knowledge of an object's weight may enable the motorizedlifting device 10 to be automatically shut off when a weight rating hasbeen exceeded; enable changes in weight to trigger various automatedresponses (e.g., lifting, lowering, or stopping the line 16); and/orprovide feedback to a user so that a load may be adjusted or more evenlydistributed among multiple motorized lifting devices 10.

The application 210 may also include a position module 244 to determinea current position of the end of the line 16. As previously mentioned,this may be accomplished using the absolute position encoder 68previously described, keeping track of the number of rotations of thedrum 14, and using a single layer of line 16 on the drum 14 to ensurethat an effective radius of the drum 14 stays constant. Using anabsolute position encoder 68 and storing position data 206 innon-volatile memory 178 will also ensure that an accurate position canbe determined even after a significant event such as a power outage.Among other benefits, the ability to accurately determine a position ofthe end of the line 16 at any given time may enable resumption ofoperation after a power outage with no need for recalibration;repeatability of operations such as returning to set points;synchronization of multiple motorized lifting devices 10; and otheradvanced operations and automation.

A grouping module 246 may be used to group multiple motorized liftingdevices 10 for synchronized operation. In certain embodiments, thegrouping module 246 enables a user to select individual devices 214 fromthe device list 212 for inclusion in the group. Once grouped, asynchronization module 248 may ensure that the motorized lifting devices10 in the group operate in a synchronized manner. For example, thesynchronization module 248 may monitor the speed and/or position of theend of the line 16 for each of the motorized lifting devices 10 in thegroup and make adjustments to the speed and/or position of othermotorized lifting devices 10 to maintain synchronization. In certainembodiments, the synchronization module 248 may be configured toidentify a slowest moving motorized lifting device 10 in the group andadjust the other motorized lifting devices 10 in the group to match thepace of the slowest motorized lifting device 10. Similarly, if amotorized lifting device 10 in the group stops for some reason (e.g., apower outage or overload condition), the synchronization module 248 mayensure that the other motorized lifting devices 10 in the group alsostop. This may prevent unsafe conditions in addition to keeping thedevices synchronized.

Instead of just ensuring that a shared load stays level, thesynchronization module 248 may also synchronize the motorized liftingdevices 10 in other ways. For example, in certain cases, it may bedesirable for a platform or other shared load to tilt and return tolevel. For example, in an automated environment such as a factory, aplatform could potentially carry granular or liquid materials that maybe poured from the platform by tilting. In such a case, thesynchronization module 248 may cause certain motorized lifting devices10 in the group to tilt the platform to perform a pouring operation. Theplatform may then be returned to level after the pouring operation iscomplete. In certain embodiments, the weight module 242 may be used todetermine that a pouring operation is complete by sensing how the weightof the platform has changed. The above example represents just one typeof advanced synchronization operation that is possible and is notintended to be limiting. Other synchronization operations are possibleand within the scope of the invention.

In certain embodiments, the application 210 includes a load distributionmanagement module 250 to assist in more optimally distributing a loadacross multiple motorized lifting devices 10. In certain embodiments,this may include providing feedback to a user regarding how much weightis supported by each motorized lifting device 10 in a group, as wasdiscussed in association with FIG. 32. Using this information, a usermay rearrange or reposition a shared load to more optimally distributethe weight across the motorized lifting devices 10 a, 10 b. In other orthe same embodiments, the load distribution management module 250 may beconfigured to provide suggestions or instructions regarding how toredistribute weight among multiple motorized lifting devices 10, asfurther discussed in association with FIG. 32.

The disclosed features and functions of the motorized lifting device 10may enable advanced capabilities and automation that may not otherwisebe possible using convention hoists or winches. These capabilities maybe useful in a wide variety of industries or professions. For example,in a hospital setting, the motorized lifting device 10 may be used tosuspend, raise, and lower a wide variety of medical tools andinstruments from a ceiling or other structure. These tools andinstruments may descend from the ceiling or structure when needed by ahealthcare practitioner. In a manufacturing environment, specializedtools may descend when required by a worker. In a lab setting,transducers or other lab equipment may be suspended from a ceiling anddescend when a specific test is required. In an automotive setting, oneor more motorized lifting devices 10 may fill an automobile with fuel orcharge an automobile battery without requiring assistance of a user.This may be accomplished, for example, using instruments such as cameras(to assist in navigation) and magnets (to assist in attachment) at theend of the line 16. Magnets may include traditional magnets orelectromagnets that may be activated and deactivated as needed. Suchmagnets may attach to magnetic regions incorporated into variousobjects. These represent just a few potential applications for themotorized lifting device 10 and are not intended to be limiting. Otherapplications are possible and within the scope of the invention.

The apparatus and methods disclosed herein may be embodied in otherspecific forms without departing from their spirit or essentialcharacteristics. The described embodiments are to be considered in allrespects only as illustrative and not restrictive. The scope of theinvention is, therefore, indicated by the appended claims rather than bythe foregoing description. All changes which come within the meaning andrange of equivalency of the claims are to be embraced within theirscope.

1. An apparatus comprising: a motor; a drum rotated by the motor to drawin or let out a line from the drum, the drum comprising a groove formedin an outer surface thereof to accommodate the line; and a rollertracking and extending into the groove in order to push the line intothe groove.
 2. The apparatus of claim 1, wherein a depth of the grooveis larger than a diameter of the line.
 3. The apparatus of claim 1,wherein the roller pushes the line to a bottom of the groove.
 4. Theapparatus of claim 1, wherein the roller is attached to a guide forguiding the line into the groove.
 5. The apparatus of claim 4, whereinthe guide is a passive guide that tracks the groove.
 6. The apparatus ofclaim 1, wherein the roller slides along an axis substantiallyperpendicular to the groove.
 7. The apparatus of claim 1, wherein thegroove is configured to grip the line.
 8. The apparatus of claim 1,wherein a width of the groove is slightly narrower than the line.
 9. Theapparatus of claim 1, wherein the groove is a helical groove.
 10. Theapparatus of claim 1, wherein the roller passively tracks the groove.11. A method comprising: rotating a drum to draw in or let out a line,the drum comprising a groove formed in an outer surface thereof toaccommodate the line; and pushing the line into the groove with a rollertracking and extending into the groove.
 12. The method of claim 11,wherein a depth of the groove is larger than a diameter of the line. 13.The method of claim 11, wherein pushing the line into the groovecomprises pushing the line to a bottom of the groove.
 14. The method ofclaim 11, further comprising guiding the line into the groove.
 15. Themethod of claim 14, wherein guiding the line into the groove comprisespassively guiding the line into the groove.
 16. The method of claim 11,wherein tracking the groove comprises sliding the roller along an axissubstantially perpendicular to the groove.
 17. The method of claim 11,wherein pushing the line into the groove comprises pushing the line intoa groove configured to grip the line.
 18. The method of claim 11,wherein pushing the line into the groove comprises pushing the line intoa groove slightly narrower than the line.
 19. The method of claim 11,wherein pushing the line into the groove comprises pushing the line intoa helical groove.
 20. The method of claim 11, wherein tracking thegroove comprises passively tracking the groove.